基于力补偿控制的三辊卷板机预弯剩余直边抑制方法研究

Research on the Method of Suppressing Residual Straight Edge in Pre-Bending of a Three-Roller Plate Bending Machine Based on Force Compensation Control

摘要: 针对对称式三辊卷板机在卷制中存在的剩余直边难题，及其导致的材料浪费、结构强度不足、装配受阻等问题，文章提出了一种基于力补偿控制的预弯抑制方法。首先，分析剩余直边产生机理与回弹力学特性，揭示力位参数与回弹量的非线性耦合关系。其次，基于弹塑性弯曲理论、卸载弹性回复原理，区分平面应力与平面应变状态并修正力学模型参数，构建融合板材参数、设备参数与加工参数的回弹量预测模型，进而设计“参数初始化–补偿量优化–闭环调控”的力位混合补偿策略，通过动态调整预弯力与位移参数补偿回弹误差，为闭环调控设计激光三角测距式实时曲率检测方案，明确硬件布局与测量精度特性。最后，通过仿真与物理样机实验验证表明，该方法可将回弹量降低98.8%以上，筒节直径偏差控制在极小范围，显著优于传统方法。该方法无需更换专用设备，适配中小型企业现有生产条件，兼顾加工精度与成本控制，为机械制造、船舶工程等领域中厚板高精度卷制提供可靠技术支撑，具有重要的工程应用价值。

Abstract: In response to the problem of residual straight edges existing in the rolling process of symmetrical three-roll plate bending machines, as well as the resulting problems such as material waste, insufficient structural strength, and assembly obstacles, this paper proposes a pre-bending suppression method based on force compensation control. First, based on the elastoplastic bending theory and the principle of elastic recovery upon unloading, the plane stress and plane strain states are distinguished, and the mechanical model parameters are corrected. A rebound prediction model integrating the parameters of the sheet material, equipment, and processing is constructed. Second, a force-position hybrid compensation strategy of “parameter initialization, compensation quantity optimization, closed-loop control” is designed. By dynamically adjusting the pre-bending force and displacement parameters, the rebound error is compensated. A laser triangulation-based real-time curvature detection scheme is designed for closed-loop control, clarifying the hardware layout and measurement accuracy characteristics. Finally, simulation and physical prototype experiments have verified that this method can reduce the rebound amount by more than 98.8%, and the diameter deviation of the cylinder section can be controlled within a very small range, which is significantly superior to traditional methods. This method does not require the replacement of special equipment, is compatible with the existing production conditions of small and medium-sized enterprises, takes into account both processing accuracy and cost control, provides reliable technical support for the high-precision rolling of medium-thick plates in fields such as mechanical manufacturing and ship engineering, and has important engineering application value.